Case Studies on the Application of Silicone Rubber Heaters in New Energy Batteries
Case Study 1: Preheating of Power Battery Modules at Low Temperatures
· Application Scenario: After being parked overnight in northern regions during winter, the temperature of lithium-ion batteries in electric vehicles drops below -10°C, making charging difficult and causing a significant decrease in discharge power.
· Solution: Custom-sized silicone rubber heaters, only 1.5–2 mm thick, are bonded to the bottom or sides of the battery modules without occupying additional space. When powered on, the heaters rapidly heat up, and the heat is evenly conducted through aluminum plates to each battery cell.
· Results: The battery pack is heated from -20°C to above 5°C within 30 minutes, restoring normal charging and discharging performance and ensuring winter range and charging speed.
· Application Scenario: After being parked overnight in northern regions during winter, the temperature of lithium-ion batteries in electric vehicles drops below -10°C, making charging difficult and causing a significant decrease in discharge power.
· Solution: Custom-sized silicone rubber heaters, only 1.5–2 mm thick, are bonded to the bottom or sides of the battery modules without occupying additional space. When powered on, the heaters rapidly heat up, and the heat is evenly conducted through aluminum plates to each battery cell.
· Results: The battery pack is heated from -20°C to above 5°C within 30 minutes, restoring normal charging and discharging performance and ensuring winter range and charging speed.
Case Study 2: Maintaining a Constant Temperature in Energy Storage Containers
· Application Scenario: When outdoor energy storage containers operate in cold regions, the internal lithium iron phosphate batteries become too cold, affecting system efficiency and cycle life.
· Solution: Large-area silicone rubber heaters are installed on the side and bottom panels of the battery clusters, working in conjunction with a temperature control system to provide automatic heating. The heaters are flexible and bendable, allowing them to conform closely to irregular surfaces during installation and ensuring even heat distribution.
· Results: By maintaining the battery operating temperature within the optimal range of 15–25°C, system charge/discharge efficiency improves by approximately 12%, and battery cycle life is extended to meet design expectations.
· Application Scenario: When outdoor energy storage containers operate in cold regions, the internal lithium iron phosphate batteries become too cold, affecting system efficiency and cycle life.
· Solution: Large-area silicone rubber heaters are installed on the side and bottom panels of the battery clusters, working in conjunction with a temperature control system to provide automatic heating. The heaters are flexible and bendable, allowing them to conform closely to irregular surfaces during installation and ensuring even heat distribution.
· Results: By maintaining the battery operating temperature within the optimal range of 15–25°C, system charge/discharge efficiency improves by approximately 12%, and battery cycle life is extended to meet design expectations.
Case Study 3: Insulation of the battery compartment at the battery swap station
Application Scenario: Spare battery packs stored in heavy-duty truck battery swap stations experience a continuous drop in temperature while on standby in extremely cold weather. After a battery swap, the vehicle must wait for the battery to self-heat before it can operate at full power.
· Solution: Integrate silicone rubber heaters into the inner walls of the battery compartment to provide continuous low-power heating while the batteries are in storage. The heaters feature a moisture-proof and weather-resistant design, making them suitable for the high-humidity, dusty environments of outdoor battery swap stations.
· Results: Standby batteries are consistently maintained above 10°C, allowing vehicles to operate at full power immediately after a battery swap. This reduces driver wait times and improves operational efficiency.
Application Scenario: Spare battery packs stored in heavy-duty truck battery swap stations experience a continuous drop in temperature while on standby in extremely cold weather. After a battery swap, the vehicle must wait for the battery to self-heat before it can operate at full power.
· Solution: Integrate silicone rubber heaters into the inner walls of the battery compartment to provide continuous low-power heating while the batteries are in storage. The heaters feature a moisture-proof and weather-resistant design, making them suitable for the high-humidity, dusty environments of outdoor battery swap stations.
· Results: Standby batteries are consistently maintained above 10°C, allowing vehicles to operate at full power immediately after a battery swap. This reduces driver wait times and improves operational efficiency.
Case Study 4: Preventing Condensation in Electric Vessel Battery Compartments
· Application Scenario: When electric ferries operate on water in southern regions during winter, significant temperature differences between the interior and exterior of the battery compartment cause condensation to form on the compartment walls, posing a threat to high-voltage electrical safety.
· Solution: Silicone rubber heaters are installed on the floor of the battery compartment. Continuous low-power heating maintains the internal temperature slightly above the dew point. The heaters feature an IP67 waterproof rating, ensuring safe and reliable operation in humid environments.
· Results: Condensation is completely eliminated, safeguarding the insulation safety of the high-voltage battery system. The low power consumption of the heating system has a negligible impact on the vessel’s range.
· Application Scenario: When electric ferries operate on water in southern regions during winter, significant temperature differences between the interior and exterior of the battery compartment cause condensation to form on the compartment walls, posing a threat to high-voltage electrical safety.
· Solution: Silicone rubber heaters are installed on the floor of the battery compartment. Continuous low-power heating maintains the internal temperature slightly above the dew point. The heaters feature an IP67 waterproof rating, ensuring safe and reliable operation in humid environments.
· Results: Condensation is completely eliminated, safeguarding the insulation safety of the high-voltage battery system. The low power consumption of the heating system has a negligible impact on the vessel’s range.
